Manufacturing pickup tool

ABSTRACT

A vacuum powered pickup tool with mechanically moveable discrete nozzles allows for selective activation of the nozzles through the mechanical movement of the nozzles relative to a vacuum manifold. The movement of a nozzle from an inactive position where an inlet port of the nozzle is fluidly decoupled with the vacuum manifold to an active position where the inlet port is fluidly coupled with the vacuum manifold allows for independent activation of discrete nozzles of the pickup tool. Aspects also contemplate varying an associate manifold through movement of the manifolds accessible to the inlet port of the nozzle when in the active position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/460,652, entitled “Manufacturing Pickup Tool,” and filed on Jul. 2,2019, which is a division of U.S. application Ser. No. 15/365,381entitled “Manufacturing Pickup Tool” and filed on Nov. 30, 2016, whichclaims the benefit of U.S. Provisional Application No. 62/261,702,entitled “Manufacturing Pickup Tool,” and filed Dec. 1, 2015. Theentirety of each of the aforementioned applications is incorporated byreference herein.

TECHNICAL FIELD

Aspects provide methods and systems for selectively activating portionsof a pickup tool for movement of a component in a manufacturingenvironment.

BACKGROUND

Manufacturing of articles may include the use of multiple discretecomponents having varying sizes and dimensions. The various componentsmay be provided in a common manufacturing setting such that commontooling is used on the various components regardless of shape and size.As such, a general tool, such as a general pickup tool, that can be usedin connection with the variety of components may be selected for themanufacturing setting to provide flexibility in the manufacturingsetting. However, a general tool when used with varying components mayintroduce inefficiencies and unintended interactions because the tool isgeneral in nature and not adapted for each of the components.

BRIEF SUMMARY

Aspects hereof provide systems and methods for a pickup tool havingindividually activated nozzles. The activation of the nozzles mayinclude individually mechanically positioning the nozzles in an activeposition relative to a vacuum manifold and an inactive position relativeto the vacuum manifold. For example, a linear actuator using pneumaticor electronic drive may linearly move the nozzle in a longitudinaldirection such that the nozzle slides through the vacuum manifold froman active position that allows for vacuum pressure to pass through thenozzle to an inactive position that prevents the negative pressurewithin the vacuum manifold from passing through the nozzle. Each of thenozzles may be individually positioned in active and inactive positionsto control which nozzles are providing vacuum pressure for picking up acomponent. Another aspect further contemplates the vacuum manifold andanother manifold, such as a positive pressure manifold, moving in thelongitudinal direction such that when a nozzle is in an active position,the manifold providing positive or negative pressure may be changed bythe linear movement of the manifolds, in an exemplary aspect. Therefore,it is contemplated that a pickup tool may have individually activatednozzles by linearly moving each nozzle relative to a manifold and themanifold that the nozzles move relative to may be changed to adjust atype/amount of pressure presented to the nozzle(s).

This summary is provided to enlighten and not limit the scope of methodsand systems provided hereafter in complete detail.

DESCRIPTION OF THE DRAWINGS

The present invention is described in detail herein with reference tothe attached drawing figures, wherein:

FIG. 1 depicts an exemplary system comprised of a pickup tool, amulti-axis movement mechanism, a vacuum source, a positive pressuresource, a computing device, a vision system, and an exemplary processsurface, in accordance with aspects hereof;

FIG. 2 depicts a cross section view of the pickup tool of FIG. 1 havingthe illustrated nozzles in active positions relative to the vacuummanifold, in accordance with aspects hereof;

FIG. 3 depicts a cross sectional view of the pickup tool of FIG. 1having the first nozzle in an active position and the second nozzle inan inactive position relative to the vacuum manifold, in accordance withaspects hereof;

FIG. 4 depicts a cross sectional view of the pickup tool of FIG. 1having the first nozzle in an active position and the second nozzle alsoin an active position relative to the positive manifold, in accordancewith aspects hereof;

FIG. 5 depicts a cross sectional view of the pickup tool of FIG. 1having the first nozzle in an active position and the second nozzle inan inactive position relative to the positive manifold, in accordancewith aspects hereof;

FIG. 6 depicts a side profile view of the pickup tool of FIG. 1 , inaccordance with aspects hereof;

FIGS. 7A-7D depict bottom views of exemplary pickup tools having nozzlespositioned in varied numbers and configurations, in accordance withaspects hereof; and

FIG. 8 depicts a flow diagram representing a method for moving materialwith a pickup tool having individually controlled nozzles, in accordancewith aspects hereof.

DETAILED DESCRIPTION

Manufacturing of articles, such as articles of footwear or articles ofapparel, may use a variety of discrete components having differentcharacteristics (e.g., material, shape, size). Each of these differentcomponents may benefit from a different pickup tool configuration formore efficient movement and placing. However, having discretelydifferent pickup tools for each of the components may introduceinefficiencies in the manufacturing process as the discrete pickup toolsare exchanged or from a tooling cost perspective. Therefore, aspectshereof contemplate a configurable pickup tool that is configured toactive discrete regions or nozzles from a plurality of regions ornozzles. The activated regions or nozzles may be configured for theunique component to be manipulated by the selectively activated portionsof the pickup tool, as will be provided hereinafter in greater detail.

At a high level, a pickup tool herein is contemplated to haveindividually activated nozzles forming the pickup tool. The activationof the nozzles may include mechanically positioning the nozzle in anactive position relative to a vacuum manifold and an inactive positionrelative to the vacuum manifold. For example, a linear actuator usingpneumatic or electronic drive may linearly move the nozzle in alongitudinal direction such that the nozzle slides through the vacuummanifold from an active position that allows for vacuum pressure to passthrough the nozzle to an inactive position that prevent the negativepressure within the vacuum manifold from passing through the nozzle.Each of the nozzles may be individually positioned in active andinactive positions to control which nozzles are providing vacuumpressure for picking up a component. Another aspect further contemplatesthe vacuum manifold and another manifold, such as a positive pressuremanifold, moving in the longitudinal direction such that when a nozzleis in an active position, the manifold providing positive or negativepressure may be changed by the linear movement of the manifolds, in anexemplary aspect. Therefore, it is contemplated that a pickup tool mayhave individually activated nozzles by linearly moving each nozzlerelative to a manifold and the manifold that the nozzles move relativeto may be changed to adjust a type/amount of pressure presented to thenozzle(s).

For example, an exemplary pickup tool may be comprised of a base member;a first movement mechanism coupled with the base member and a secondmovement mechanism coupled with the base member. The first movementmechanism and the second movement mechanism are independentlycontrollable. The pickup tool is further comprised of a vacuum manifoldthat is coupled, fixedly or moveably, with the base member and comprisedof a first sleeve and a second sleeve extending through the vacuummanifold. The first sleeve is comprised of a first sleeve port and thesecond sleeve is comprised of a second sleeve port such that the firstsleeve port and the second sleeve port are apertures that extend throughthe first sleeve and the second sleeve, respectively, and fluidlyconnect an internal volume of the vacuum manifold with the first sleeveand the second sleeve, respectively. The pickup tool is furthercomprised of a first nozzle having a first inlet port fluidly connectedwith a first pressure port of the first nozzle. The first nozzle isphysically connected with the first movement mechanism and slidablymoveable in a longitudinal direction within the first sleeve and thefirst nozzle is configured to be positioned at an active position and aninactive position within the first sleeve by the first movementmechanism. The pickup tool is also comprised of a second nozzle having asecond inlet port fluidly connected with a second pressure port of thesecond nozzle. The second nozzle is coupled with the second movementmechanism and slidably moveable within the second sleeve and the secondnozzle is configured to be positioned at an active position and aninactive position by the second movement mechanism within the secondsleeve.

With a broader perspective, aspects herein provides for a materialpickup system that includes a computing device; a vacuum source; amulti-axis movement device logically coupled with the computing device;and a pickup tool logically coupled with the computing device. Thepickup tool includes a plurality of independently activated nozzles anda plurality of nozzle movement mechanisms. Each of the plurality ofindependently activated nozzles is coupled with a discrete nozzlemovement mechanism of the plurality of nozzle movement mechanism. Thepickup tool is also comprised of a vacuum manifold that is fluidlycoupled with the vacuum source. Each of the plurality of independentlyactivated nozzles slidably extends through respective manifold sleevesof the vacuum manifold. As a nozzle slides within a manifold sleeve by aforce applied, in part, by a nozzle movement mechanism, the nozzle canchange positions between an active position where the pressure (e.g.,negative pressure) of the vacuum manifold is fluidly transmitted to thenozzle allowing the nozzle to use that pressure as a pickup tool and aninactive position where the pressure of the vacuum manifold is nottransmitted through the nozzle.

Further yet, methods are contemplated herein for moving material with apickup tool. The method includes moving a nozzle of a plurality ofnozzles relative to a vacuum manifold of the pickup tool to fluidlycouple an inlet port of the first nozzle with a sleeve port of thevacuum manifold. This movement allows for pressure within the vacuummanifold to be transmitted through the nozzle to a component to bepicked up by the pickup tool. The method continues with positioning thepickup tool proximate the first component such that the first nozzle ispositioned proximate a component at a first location to be picked up bythe pickup tool and moving the component as maintained to the pickuptool by at least the first nozzle. The method further includes placingthe component at a second location and moving the first nozzle relativeto the vacuum manifold to fluidly decouple the inlet port from thesleeve port. The decoupling prohibits the transmission of the internalpressure of the vacuum manifold through the nozzle, which caneffectively stop a continued vacuum force at the nozzle interface withthe component. The method may optionally include moving a positivemanifold relative to the nozzle such that the inlet port of the nozzleis in fluid communication with a positive sleeve port of the positivemanifold. In this step, a positive pressure may be transmitted from thepositive manifold through the nozzle to dislodge the component from thenozzle, such as through a blowing off action. The positive manifold, inthis example, is coupled with the vacuum manifold such that the positivemanifold and the negative manifold move in cooperation relative to thenozzle.

Additional aspects will be provided herein. For example, FIG. 1 depictsan exemplary system 100 comprised of a pickup tool 102, a multi-axismovement mechanism 104, a vacuum source 106, a positive pressure source108, a computing device 110, a vision system 114, and an exemplaryprocess surface 112, in accordance with aspects hereof. Additionallydepicted are a plurality of varied exemplary components, such ascomponent 116, component 118, and component 120. While a variety ofdevices, elements, and components are depicted in FIG. 1 , it iscontemplated that additional devices, elements, and components may beimplemented in alternative aspects. Further, it is contemplated that oneor more of the devices, elements, and components may be omittedaltogether. Further yet, it is contemplated that any combination and/ornumber of devices, elements, and components may be utilized in exemplaryaspects hereof. Therefore, FIG. 1 is illustrative and not intended to belimiting in nature.

The pickup tool 102 is depicted in a simplified form for illustrationpurposes and will be explained in greater detail with respect to FIGS.2-7D hereinafter. However, at a high level, the pickup tool 102 providesa plurality of individually controllable zones, which may be defined byindividually controllable nozzles representing each zone. However, agrouping of nozzles may represent a particular zone and while eachnozzle within a given zone can be independently activated in someaspects, it is also contemplated that a grouping of nozzles forming azone may be activated in cooperation, such as through a common nozzlemovement mechanism, in an exemplary aspect. Examples providedhereinafter refer to individually controlled nozzles, but it isunderstood that groupings of elements are also contemplated.

The multi-axis movement mechanism 104 may be a robotic arm having avariety of degrees of motion and/or rotation. For example, a 2, 3, 4, 5,6, 7 degrees of freedom multi-axis movement mechanism may be coupledwith the pickup tool 102 to position the pickup tool 102 in a particularlocation of the working environment to pick up and place a component.For example, the multi-axis movement mechanism 104 may be logicallycoupled with the computing device 110 to receive one or moreinstructions (or to provide one or more feedback indications) toappropriately position the pickup tool 102.

The vacuum source 106 is a vacuum generating device capable of creatinga negative pressure that is fluidly coupled with the pickup tool 102,such as through flexible tubing that provides flexibility to themovement and positioning of the pickup tool 102 by the multi-axismovement mechanism 104. Vacuum generating devices may generate anegative pressure (e.g., vacuum) through a variety of means, such ascoanda effect, venture effect, powered decompressors (e.g., electric,pneumatic, hydraulic powered), and the like. It is contemplated that thevacuum source 106 is logically coupled, in an exemplary aspect, with thecomputing device 110 to control the amount of vacuum, the presence ofvacuum, and the like. For example, as vacuum pressure needs change, thecomputing device may control an amount of vacuum pressure generated.Additionally, it is contemplated that as the presence (e.g., on/off) ofvacuum pressure changes, the computing device 110 may provideappropriate instructions to control the vacuum source 106, in anexemplary aspect.

The positive pressure source 108 is a pressure generator, such as acompressor. The positive pressure source 108 is fluidly coupled with thepickup tool 102 to provide a positive air pressure (e.g., compressedair). The positive pressure may be used at the pickup tool 102 toactivate one or more pneumatic movement mechanisms (e.g., pneumaticactuators). The positive pressure may alternatively or additionally beused to provide positive pressure to a positive manifold for applicationof pressurized air through one or more nozzles to cause a blow offeffect, as will be provided hereinafter. It is contemplated that thepositive pressure source 108 is logically coupled with the computingdevice 110 to control the distribution of positive pressure. Forexample, one or more valves may be associated with the positive pressuresource 108 that allow for individual control of one or more uniquemovement mechanisms, such as nozzle movement mechanisms and/or manifoldmovement mechanisms. Additionally or alternatively, it is contemplatedthat the controlling valves may be associated with an alternativedevice, such the pickup tool 102 for the individual control of one ormore movement mechanisms. Further, it is contemplated that the positivepressure source 108 does not provide power for one or more movementmechanisms, but instead serves as a positive pressure source for anoptional positive manifold or it is omitted altogether, in some aspects.

The computing device 110 has a processor and memory and is functional toprovide instructions, receive information, access information, andprocess the received and accessed information. As such, it iscontemplated that the computing device 110 is logically coupled eitherwired or wirelessly to one or more of the elements of the system 100.For example, the computing device may be couple with the vision system114 to identify an orientation and identification of a component. Thecomputing device 110 may then instruct the pickup tool 102 to activateone or more nozzles effective to pick up or otherwise manipulate theidentified component. The computing device 110 may also instruct themulti-axis movement mechanism 104 to position the pickup tool 102 in oneor more locations. Further, it is contemplated that computing device 110may coordinate said actions to accomplish the movement, pick, and placeof a component with the pickup tool 102.

The computing device 110 may include a variety of computer-readablemedia. Computer-readable media can be any available media that can beaccessed by computing device 110 and includes both volatile andnonvolatile media, removable and non-removable media. By way of example,and not limitation, computer-readable media may comprise computerstorage media and communication media. Computer storage media includesvolatile and nonvolatile, removable and non-removable media implementedin any method or technology for storage of information such ascomputer-readable instructions, data structures, program modules, orother data.

Computer storage media includes non-transitory RAM, ROM, EEPROM, flashmemory or other memory technology, CD-ROM, digital versatile disks (DVD)or other optical disk storage, magnetic cassettes, magnetic tape,magnetic disk storage, or other magnetic storage devices. Computerstorage media does not comprise a propagated data signal.

Communication media typically embodies computer-readable instructions,data structures, program modules, or other data in a modulated datasignal such as a carrier wave or other transport mechanism and includesany information delivery media. The term “modulated data signal” means asignal that has one or more of its characteristics set or changed insuch a manner as to encode information in the signal. By way of example,and not limitation, communication media includes wired media such as awired network or direct-wired connection, and wireless media such asacoustic, RF, infrared, and other wireless media. Combinations of any ofthe above should also be included within the scope of computer-readablemedia.

The computing device 110 may include computer-readable media havinginstruction embodied thereon that are effective to cause one or moreelements of the system 100 to perform one or more actions. For example,the instructions may cause a movement mechanism to move, a multi-axismovement device to move, a camera to capture an image, a register toregister a position of the material, and a processes station to performan operation, in an exemplary aspect.

The process surface 112 is a surface on which a component may beaccessed by the pickup tool 102. For example, it is contemplated thatthe process surface 112 is a conveyance surface, such as a conveyorbelt. For example, a component may move along the process surface 112within a capture area of the vision system 114 to identify a relativeorientation, position, and potential identification of the component.The component may continue to advance along the process surface 112 to aworkable zone accessible by the pickup tool 102 that may then pick upthe component for additional processing (e.g., movement to a differentlocation, positioning relative to another component, and/orrepositioning/orienting the component).

The vision system 114 is effective to capture an image. For example, thevision system may be a camera capable of capturing an image of one ormore components. The image may be communicated to a computing device,such as the computing device 110. The image may then be analyzed by thecomputing device. The analysis may determine an identification of thecomponent, an orientation of the component, and/or a position of thecomponent. These determinations may then be used in connection withstored information to determine an appropriate action for the pickuptool 102. For example, a determination as to which nozzles toactive/deactivate, a position of the pickup tool 102 to be placed by themulti-axis movement mechanism 104, and position to place the componentonce secured by the pickup tool 102, in an exemplary aspect.

The component 116, component 118, and component 120 are exemplary innature. These components may be portions of materials, rigid orflexibly, that are used in the formation of an article, such as anarticle of footwear. The components may be of any size, shape, material,and orientation. For example, as depicted, each of the components 116,118, and 120 have a different shape and size. The pickup tool 102 mayactivate different nozzles thereon in response to the shape and size ofeach of the components. This selective activation of nozzles may preventexcess vacuum pressure use and/or unintentional adhesion of elements tothe pickup tool other than a target component, for example.

The components may be made of any material, such as knit, woven, film,sheet, leather, mesh, non-woven, and the like. For example, a firstcomponent may be formed from a porous mesh-like material and a secondcomponent may be formed from a polymer film. The mesh-like material maybe more difficult to maintain with vacuum pressure than the non-porouspolymer film; therefore, a different nozzle configuration may beselected based on the component material (e.g., more nozzles may beactivated for the mesh-like material than the non-porous film).

As previously provided, the components, elements, and devices of system100 are illustrative in nature and are not limiting. Additional and/oralternative components, elements, and device may be implemented. Forexample multiple vision systems, multiple pickup tools, multiplecomputing devices, and/or multiple vacuum/pressure sources may be usedin exemplary aspects. Further, one or more components, elements, and/ordevices may be omitted in exemplary aspects.

FIGS. 2-5 illustrate various configurations of the pickup tool 102 ofFIG. 1 , in accordance with aspects hereof. For example, FIGS. 2 and 3depict the pickup tool 102 having nozzles in various states of inactiveand active positioning relative to a first manifold, such as a vacuummanifold 204. FIGS. 4 and 5 depict the pickup tool 102 having nozzles invarious states of inactive and active positioning relative to a secondmanifold, such as a positive manifold 206. As such, it is illustratedhow the pickup tool 102 is configured to independently activate nozzleswith a linear movement through one or more manifolds while changing themanifold to which the nozzles are able to fluidly couple. While twomanifolds are depicted in FIGS. 2-5 , it is understood that aspectshereof contemplate a single manifold without additional manifoldoptions. For example, it is contemplated that a first pressure source(e.g., vacuum pressure) and a second pressure source (e.g., positivepressure) may be coupled with a common manifold and the pressure of themanifold may be changed without changing the manifold that the nozzlesmay be in fluid communication herewith by changing the pressure sourceto the manifold. Therefore, while not depicted, it is contemplated thata single manifold configuration may be implemented.

While a plurality of nozzles are depicted in FIGS. 1-7D, aspects hereininclude a single nozzle and not a plurality of nozzles. For example, aunitary nozzle may be implemented in an exemplary aspect. Further, it iscontemplated that at a basic level, a single nozzle and a single nozzlemovement mechanisms may be used in connection with one or more manifoldsto achieve aspects hereof. Therefore, while the illustrated examplesdepict a plurality of nozzles, it is contemplated that a single nozzlethat mechanically moves to fluidly couple and decouple with a manifoldmay be implemented to achieve aspects contemplated herein.

FIG. 2 depicts a cross section view 200 of the pickup tool 102 havingthe illustrated nozzles in active positions relative to the vacuummanifold 204, in accordance with aspects hereof. The pickup tool 102 iscomprised of a base plate 202, a vacuum manifold 204, a positivemanifold 206, a first nozzle movement mechanism 208, a first nozzle 210,a first sleeve 212, a first sleeve port 214, a second sleeve 215, apositive sleeve port 216, an inlet port 218, a pressure port 220, apressure channel 222, seals 224, 226, 228, 230, a vacuum manifoldinternal volume 232 and a positive manifold internal volume 234, amanifold movement mechanism 236, a second nozzle 211, and a secondnozzle movement mechanism 213.

The pickup tool 102 is illustrated for discussion purposes. It iscontemplated that alternative features/elements, combinations offeatures/elements, numbers of features/elements, and positions offeatures/elements may be implemented. For example, only three nozzlesare depicted in FIG. 2 , however, it is contemplated that any number ofnozzles may be implemented within the scope of aspects contemplated. Forexample, a first pickup tool may have 255 nozzles, a second pickup toolmay have 100 nozzles, a third pickup tool may have 50 nozzles, a fourthtool may have 20 nozzles, a fifth pickup tool may have 10 nozzles, and asixth tool may have 2 nozzles. Further to that, it is contemplated thatany number of nozzles may be implemented in any configuration, as willbe explored in FIGS. 7A-7D hereinafter. Similarly, it is contemplatedthat any number of movement mechanisms may be implemented, such asdiscrete nozzle movement mechanisms per nozzle or several nozzlescoupled with a common nozzle movement mechanism. Additionally, asalready discussed herein, it is contemplated that a single manifold isimplemented in a pickup tool. So, while two discrete manifolds areprovided in FIGS. 2-6 , a unitary manifold configuration is alsocontemplated. The number and existence of manifold movement mechanismsmay also be adjusted based on the size and number of manifolds. Forexample, when a single manifold configuration is implemented, themanifold movement mechanism may be omitted altogether. Therefore, theelements and features of the pickup tool 102 are exemplary in nature andare not limiting to the scope contemplated herein.

The base plate 202 is an anchor element to which one or more movementmechanisms are secured. For example, the first nozzle movement mechanism208 is secured to the base plate 202, such as threadably secured therethrough. The manifold movement mechanism 236 is also depicted as beingsecure to the base plate 202. As depicted, the movement mechanismsextend through the base plate 202 from a top surface to a bottomsurface; however, it is contemplated that a movement mechanism may besecured to the bottom surface of the base plate 202 in an exemplaryaspect. Further, while the base plate 202 is depicted as a discrete andseparate piece from the vacuum manifold 204, in an exemplary aspect thebase plate 202 and the vacuum manifold 204 may be a singular element orrigidly coupled together. Further, while an offset distance 316 isdepicted there between, the offset distance 316 may be any distanceincluding an abutment of the base plate 202 bottom surface with thevacuum manifold 204, in an exemplary aspect. The base plate 202 may beformed from any material, such as a metallic material (e.g., aluminum,steel, magnesium), a polymer-based material (e.g., polystyrene, vinyl,polyethylene, polypropylene, polyethylene terephthalate, polyvinylchloride) composite (e.g., fiber reinforced materials), and the like.Further, the base plate may be formed from milling, molding, additivemanufacturing (e.g., deposition, sintering) and/or the like.

The base plate 202 may also serve, directly or indirectly, as aconnection point with the multi-axis movement mechanism 104 of FIG. 1 .For example, a mounting bracket may be removably secured or integrallyformed with the base plate 202 for securing the pickup tool 102 to themulti-axis movement mechanism 104 of FIG. 1 , for example.

The vacuum manifold 204 provides a structure through which a pluralityof nozzles slideable move and provides the internal volume 232 thatmaintains an air pressure, such as a negative air pressure (i.e., avacuum pressure). As such, the vacuum manifold 204 provides structuralsupport for maintaining the axial alignment (e.g., longitudinal axis310, 312, and 314) of the plurality of nozzles as they slide through thevacuum manifold 204. Additionally, the vacuum manifold 204 providesstructural support to resist deformation from the pressure of theinternal volume 232, such as a contracting deformation provided by anegative pressure or an expanding deformation provided by a positivepressure.

The vacuum manifold 204 may be formed from any material, such as ametallic material, a polymer-based material, and/or a compositematerial. Additionally, it is contemplated that the vacuum manifold isformed from a variety of manufacturing techniques, such as milling,molding, and/or additive manufacturing. For example, in an exemplaryaspect, the vacuum manifold is formed from an additive process, such aslaser sintering, to form the complex internal geometries of the vacuumsleeve and sleeve ports. For example, because the vacuum manifold may beformed with internal elements (e.g., the sleeves) of an enclosed volume(e.g., internal volume 232), additive manufacturing allows for thebuilding of those geometries while still achieving an enclosed volumeeffective to maintain an air pressure (e.g., positive or negative).However, it is also contemplated that the vacuum manifold 204 may beformed from separate elements and assembled to achieve the internalelements, in an exemplary aspect.

The positive manifold 206 provides a structure through which a pluralityof nozzles slideable move and provides the internal volume 234 formaintaining an air pressure, such as a positive air pressure (i.e., acompressed air pressure). As such, the positive manifold 206 providesstructural support for maintaining the axial alignment (e.g.,longitudinal axis 310, 312, and 314) of the plurality of nozzles as theyslide through the positive manifold 206. Additionally, the positivemanifold 206 provides structural support to resist deformation from thepressure of the internal volume 234, such as a contracting deformationprovided by a negative pressure or an expanding deformation provided bya positive pressure.

The positive manifold 206 may be formed from any material, such as ametallic material, a polymer-based material, and/or a compositematerial. Additionally, it is contemplated that the positive manifold206 is formed from a variety of manufacturing techniques, such asmilling, molding, and/or additive manufacturing. For example, in anexemplary aspect, the positive manifold 206 is formed from an additiveprocess, such as laser sintering, to form the complex internalgeometries of the positive sleeves and sleeve ports. For example,because the positive manifold 206 may be formed with internal elements(e.g., the sleeves) of an enclosed volume (e.g., internal volume 234),additive manufacturing may be used for building of those geometrieswhile still achieving an enclosed volume effective to maintain an airpressure (e.g., positive or negative). However, it is also contemplatedthat the positive manifold 206 may be formed from separate elements andassembled to achieve the internal elements, in an exemplary aspect.

If two or more manifolds are used in conjunction with a pickup tool, itis contemplated that the first manifold (e.g., vacuum manifold 204) andthe second manifold (e.g., positive manifold 206) have axially alignedsleeves allowing for the axial movement of a nozzle through bothmanifolds. For example, the vacuum manifold 204 has the first sleeve 212that surrounds a circumference of the first nozzle 210 and allows forthe first nozzle 210 to slide along the longitudinal axis 310 throughthe vacuum manifold 204. The positive manifold 206 includes acomplimentary second sleeve 215 that also surrounds the circumference ofthe first nozzle 210 and allows for the first nozzle 210 to slide alongthe longitudinal axis 310 through the positive manifold 206. Stateddifferently, the vacuum manifold 204 and the positive manifold 206 arepositioned relative to each other to allow for the longitudinal movementof a nozzle through both manifolds.

A nozzle, such as the first nozzle 210, is effective to transmit airpressure (e.g., positive or negative) from a manifold to apart-contacting surface of the nozzle, such as a surface at the pressureport 220 of the first nozzle 210. The nozzle is comprised of an inletport, such as the inlet port 218, that extends from an exterior surfaceof the nozzle toward an internal channel connected with the pressureport. For example, the first nozzle 210 has the inlet port 218 extendingin a direction substantially perpendicular to the longitudinal axis tothe pressure channel 222 that terminates in the pressure port 220 at apart-contacting surface of the first nozzle 210. The inlet port,pressure channel, and pressure port are effective to fluidly couple aninternal volume of a manifold with an exterior location at thepart-contacting surface of the nozzle.

The nozzle(s) may be formed from any material, such as a metallic orpolymer-based material. Further, it is contemplated that the nozzle maybe formed from a plurality of materials, such as a rigid materialforming a longitudinal shaft and a part-contacting surface formed from apliable and adaptable material to form a seal at the pressure port 220to effectively adhere a component thereto. A size of the nozzle in alongitudinal direction may range from 5 millimeters (“mm”) to 400 mm inexemplary aspects. A diameter of a nozzle may range from 1 mm to 40 mmin an exemplary aspect.

A nozzle movement mechanism, such as the first nozzle movement mechanism208 and the second nozzle movement mechanism 213, may be any movementmechanism, such as a linear actuator. A linear actuator is capable ofmoving the nozzle in a linear direction, such as in a direction alignedwith the longitudinal axis 312 of the first nozzle 210. A linearactuator may be powered by a variety of means, such as an electric motor(e.g., converting rotational movement to linear movement through athreaded rotation of a shaft), pneumatic energy (e.g., pressurized gasdriving a piston within an appropriately sized cylinder), hydraulicenergy (e.g., pressurized liquid driving a piston within anappropriately sized cylinder), and the like. Therefore, it iscontemplated that a nozzle movement mechanism is effective to position anozzle in at least two positions, such as an active position (e.g.,represented by a plane 304) and in an inactive position (e.g.,represented by a plane 302 and as best seen in FIG. 2 ). As will bediscussed herein, the linear movement of the nozzle between at least theactive and inactive positions allows for the fluid coupling anddecoupling of the nozzle with a selected manifold.

The nozzle movement mechanisms in FIG. 2 are illustrated in basic termsfor ease of understanding. As such, it is contemplated in reality thatone or more additional details exists, such as a piston and cylinder, amotor and threaded rod, or other components effective to translate asupplied power into a movement able to manipulate a position of aconnected nozzle. Further, the first nozzle movement mechanism 208 andthe second nozzle movement mechanism 213 are depicted as having abiasing element 225 (e.g., spring) that resists the movement of thenozzle into the active position such that when a supplied power source(e.g., pressurized air in the case of a pneumatic movement mechanism) iswithdrawn, the biasing element returns the nozzle to an inactive state.This natural tendency to be in an inactive state allows for pressurewithin the manifold positioned for fluid coupling with nozzle to bemaintained even if the power supply to the nozzle movement mechanisms isinterrupted (e.g., an air supply line to a pneumatic actuator rupturesor an air-supply valve malfunctions). While a spring biasing member isdepicted, it is contemplated that any biasing member may be implementedor omitted altogether. For example, a dual direction movement mechanismmay be used that actively moves in both a first direction and anopposite second direction with active power supplied (e.g., forward andreverse linear actuation motion).

As will be provided in greater detail hereinafter, a distance ofmovement provided by a nozzle movement mechanism is at least an amountsufficient to position an inlet port within a sleeve port for fluidlycoupling the nozzle with the associate manifold and to position theinlet port outside of the sleeve port to fluidly decouple the nozzlefrom the associated manifold. For example, the first sleeve port 214 hasa longitudinal length represented by distance 322. In order to ensure adecoupling of the first nozzle 210 from the first sleeve port 214, theinlet port 218 is moved a distance 320 that moves the inlet port 218outside of the sleeve port as sealed by ring seals 224 and 226, in thisexample. However, it is contemplated that the distance 320 of movementbetween an active and an inactive position may be less than the distance322. For example, the inlet port 218 may move from adjacent sides of aseal, e.g., seal 224, to transition from an active to an inactiveposition, in an exemplary aspect. For example, the inlet port may have adiameter represented by a distance 324 and in this example the totalmovement of the nozzle is at least the distance 324 to ensure a completefluid coupling and decoupling. Therefore, the throw distance, ordistance of movement supplied by a nozzle movement mechanism is at leasta sufficient amount to move an inlet port from a first side of a sealforming a sleeve port and an opposite second side of the seal formingthe sleeve port.

A sleeve, such as the first sleeve 212, is a structure extending througha manifold that guides the movement of a nozzle extending there throughand also provides a sealed region including a sleeve port, such as thefirst sleeve port 214 as sealed by the seals 224, 226. As a result, thesleeve provides for the linear movement and lateral support of a nozzlethrough a manifold thickness. A sleeve may be shaped and sized tosurround an outer surface of a nozzle while allowing for the slideablemovement of the nozzle through the sleeve and for allowing of a seal tobe formed to limit leakage between the nozzle and the sleeve. In anexemplary aspect a sleeve is a cylinder shape extending through themanifold and includes an air passage through the sleeve to fluidlycouple the internal volume of the manifold (e.g., internal volume 232)with the sleeve port (e.g., first sleeve port 214). The fluid connectionbetween the manifold and the sleeve port by way of the air passageextending through the sleeve allows for the transmission of fluid fromthe manifold to the pressure port of one or more nozzles in the activeposition, in an exemplary aspect.

A sleeve may be a discrete structure extending through the manifold asdepicted in FIGS. 2-5 . Alternatively, the sleeve may be formed from atop surface and a bottom surface of the manifold through which thenozzle extends. For example, an aperture on the top surface and anaxially aligned aperture on a bottom surface of a manifold may be sizedto receive and allow a sealed and slideable movement of a nozzle therethrough while still supporting and guiding the movement of the nozzle.Therefore, in this simplified example, the sleeve port is also theinternal volume of the manifold such that an active position includeshaving a nozzle inlet port positioned within the manifold internalvolume and an inactive position includes that the nozzle inlet portoutside of the manifold internal volume, in an exemplary aspect.Therefore, it is contemplated that a variety of structures may beimplemented to achieve the coupling and decoupling of a nozzle with amanifold.

In an optional aspect, the pickup tool 102 is comprised of two manifoldhaving different pressure characteristics. For example, the vacuummanifold 204 may contain a negative pressure that is effective to createa suction effect at the pressure port of the nozzles, and the positivemanifold 206 may contain a positive pressure that is effective to createa blow off effect at the pressure port of the nozzles, in an example. Totransition the pickup tool between the vacuum manifold 204 and thepositive manifold 206, the manifold movement mechanism 236 collectivelymoves the manifolds. The collective movement of the manifold positions arequested manifold within a region allowing for the nozzles to changebetween an active and in active position for the selected manifold.Stated differently, the nozzles continue to only move between the plane304 and the plane 302 to fluidly couple and decouple from anappropriately positioned manifold. To change which manifold is theappropriately positioned manifold, the manifold movement mechanism 236linearly positions the manifolds relative to the base plate 202. As seenin FIGS. 2 and 3 the offset distance 316 is maintained between thebottom surface of the base plate 202, as represented by plane 308, andthe top surface of the vacuum manifold 204 as represented by plane 306.When the positive manifold 206 is appropriately positioned to be fluidlycoupled with the nozzles of the pickup tool 102, as depicted in FIGS. 4and 5 , a distance 313 is provided between the base plate 202 and theplane 306. With the movement of the manifolds relative to the base plate202, the part contacting surface position for the nozzles remainsconstant when in the active position as depicted by the plane 304.Therefore, a component may be adhered to one or more active nozzles withthe vacuum manifold 204 appropriately positioned and the component maybe blown off of the one or more active nozzles by linearly moving themanifold via the manifold movement mechanism 236 until the positivemanifold 206 is appropriately positioned to fluidly couple with thestill actively positioned nozzles, in an example.

The manifold movement mechanism 236 may be a linear actuator. Aspreviously provided, the linear actuator may be powered by a variety ofmeans, such as electric power, pneumatic power, and/or hydraulic power,for example. The manifold movement mechanisms may be able to linearlymove any distance suitable to accomplish aspects provided herein. Forexample, a distance 318 extends between a midpoint of the first sleeveport 214 and a midpoint of the positive sleeve port 216. To center theinlet port 218 of the first nozzle 210 when maintained in an activeposition, the manifold movement mechanism 236 moves at least a distance318, in an exemplary aspect. Stated differently, in an exemplary aspect,the offset distance 316 is at least equal to the distance 318 allowingfor an inlet port of a nozzle to be similarly positioned relative to asleeve port of different manifolds. However, the offset distance 316 maybe less than the distance 318 if a consistent relative position of aninlet port to different sleeve ports is not utilized. Further yet, in anexemplary aspect, the manifold movement mechanism is effective to moveat least a distance between the seal 226 and the seal 228 to ensure thenozzle is able to fluidly couple with both the vacuum manifold 204 andthe positive manifold 206. In an exemplary aspect, the first inlet port218 is not in fluid communication with the first sleeve port 214 nor thefirst positive sleeve port 216 when the first nozzle 210 is in aninactive position.

The elements and features of the positive manifold 206 may be similar tothose discussed with respect to the vacuum manifold 204, in an exemplaryaspect. For example, the first sleeve 212 and the second sleeve 215 mayhave a similar construction, size, and shape. Further, as previouslyprovided, the opening of the sleeves through which the nozzles extendmay be axially aligned for a smooth slideable motion of the nozzlerelative to the manifolds.

FIG. 3 depicts a cross sectional view 300 of the pickup tool 102 havingthe first nozzle 210 in an active position and the second nozzle 211 inan inactive position relative to the vacuum manifold 204, in accordancewith aspects hereof. The second nozzle 211 is positioned by the secondnozzle movement mechanism 213 at the inactive position represented bythe plane 302. In this inactive position, a second inlet port 326 isfluidly decoupled from the second sleeve port 328 by being positionedabove a seal defining the top of the second sleeve port 328. As such,the second nozzle 211 is positioned outside of a part contacting planedefined by the active position of plane 304, which reduces interferenceof the inactive nozzle with the components to be manipulated, in anexemplary aspect.

FIG. 4 depicts a cross sectional view 400 of the pickup tool 102 havingthe first nozzle 210 in an active position and the second nozzle 211also in an active position relative to the positive manifold 206, inaccordance with aspects hereof. As depicted, the manifolds arerepositioned by the manifold movement mechanism 236 such that the inletport 218 is fluidly coupled with the positive sleeve port 216 allowingfor transmission of pressure from the positive manifold 206 through thefirst nozzle 210. In this example, the manifold movement mechanism 236linearly moved the manifolds a distance equivalent to the distance 318allowing for a consistent inlet port position relative to the differentmanifolds when in the active position. This movement of the manifoldscauses a distance between the base plate 202 bottom surface and theplane 306 to reduce to a distance 313, in this example. As previouslyprovided, however, the distance of movement by the manifold movementmechanism 236 may vary while still allowing the effective coupling anddecoupling of a nozzle with various manifolds.

FIG. 5 depicts a cross sectional view 500 of the pickup tool 102 havingthe first nozzle 210 in an active position and the second nozzle 211 inan inactive position relative to the positive manifold 206, inaccordance with aspects hereof. As previously discussed with respect toFIG. 4 , the manifold movement mechanism 236 repositions the manifoldssuch that the positive manifold 206 is positioned to be coupled with thefirst nozzle 210, in this example. Also similar to FIG. 3 in which thesecond nozzle 211 is positioned in an inactive position at the plane 302by the second nozzle movement mechanism 213. However, in FIG. 5 , thesecond nozzle is decoupled from the positive manifold 206 where thesecond inlet port 326 is fluidly decoupled from a positive second sleeveport 327.

FIG. 6 depicts a side profile view 600 of the pickup tool 102, inaccordance with aspects hereof. As depicted, the first nozzle 210 andthe second nozzle 211 extend through the vacuum manifold 204 and thepositive manifold 206. A vacuum supply line 602 fluidly couples thevacuum manifold 204 with a vacuum source, such as the vacuum source 106of FIG. 1 . A pressure supply line 604 fluidly couples the positivemanifold 206 with a positive pressure source, such as the positivepressure source 108 of FIG. 1 . The manifold movement mechanisms arecoupled with supply lines 606 and 608 that provide connectivity with apower source, such as a positive pressure source, an electricalcontroller, or other source. Therefore, the supply lines 606 and 608 maybe fluidly or electrically coupled with one or more power sources tocause the movement of the manifold movement mechanisms. Similarly, thenozzle movement mechanisms are coupled with supply lines 610, 612, and614 that provide connectivity with a power source, such as a positivepressure source, an electrical controller, or other source. Therefore,the supply lines 610, 612, and 614 may be fluidly or electricallycoupled with one or more power sources to cause the movement of thenozzle movement mechanisms. It is contemplated that one or moreswitches, valves, or controllers may be directly or indirectlyassociated with one or more movement mechanisms and/or supply lines tocontrol associated movements. For example, a computing device mayprovide instructions to the one or more switches, valves, and/orcontrollers to regulate and control the distribution of power to themovement mechanisms, in an exemplary aspect.

FIGS. 7A-7D depict bottom views of exemplary pickup tools having nozzles704 positioned in varied numbers and configurations, in accordance withaspects hereof. FIG. 7A depicts a square pickup tool 702 having astaggered distribution of nozzles 704, in accordance with aspectshereof. FIG. 7B depicts a rectangular pickup tool 706 having a lineararrangement of nozzles 704, in accordance with aspects hereof. FIG. 7Cdepicts another rectangular pickup tool 708 having a staggeredarrangement of nozzles 704 in accordance with aspects hereof. FIG. 7Ddepicts a square pickup tool 710 having limited number of nozzles 704 ina staggered arrangement, in accordance with aspects hereof.

It is contemplated that any number of nozzles, configuration of nozzles,and orientation of nozzles may be implemented. As previously discussed,as many as 300 discrete and individually controllable nozzles may beimplemented and as few as 2 discrete and individually controllablenozzles may be implemented in aspects hereof. Further, any shape, suchas circular, oval, irregular, rectangular, square, and the like may beimplemented as the configuration to which the nozzles are arranged.

FIG. 8 depicts a flow diagram representing a method 800 for movingmaterial with a pickup tool having individually controlled nozzles, inaccordance with aspects hereof. At a block 802 a first component iscaptured with a vision system. For example, a component to form anarticle of footwear may be presented within a field of view of thevision system such that an image is captured from the vision system.This captured image may then be analyzed to determine a componentidentification and/or orientation. From this determination, the one ormore stored instructions may be retrieved that determine which of aplurality of nozzles should be activated for the component. Theseinstructions may be maintained in a computing device controlling themovement and activation of the pickup tool, in an exemplary aspect.

At a block 804 a first nozzle is moved relative to a vacuum manifold ofthe pickup tool to fluidly couple the first nozzle with a sleeve port ofthe vacuum manifold. This movement may be accomplished by a nozzlemovement mechanism, such as a linear actuator. The selection of thefirst nozzle to become active may be made by a computing device inresponse to a known component to be picked up.

At a block 806 the pickup tool is positioned proximate the componentsuch that at least the first nozzle is positioned proximate thecomponent. The positioning of the pickup tool may be accomplished by amulti-axis movement mechanism, such as a robotic arm. The positioning ofthe pickup tool may be controlled and coordinated by a computing device,in an exemplary aspect.

At a block 808 the component is moved by the pickup tool such that thecomponent is removably adhered to the first nozzle by a vacuum force.The vacuum force is transmitted by the first nozzle as a result of thestep in block 804. Additional nozzles of the pickup tool not in anactive position (e.g., decoupled from the vacuum manifold) do notremovably adhere to the component as they are not transmitting a vacuumpressure and they may be physically recessed from the part-contactingplane, in an exemplary aspect.

At a block 810 the component is placed at a location by the pickup tool.IN an exemplary aspect, the component is re-oriented for anotherprocessing step to be performed (e.g., sewing, cutting, adhering,painting, and printing). The component may be stacked or positionedrelative to another component in an exemplary aspect at the block 810.The component may be transferred to another processing line or machineat the block 810. In an exemplary aspect, the placing of the componentmay be accomplished through a blow off of positive pressure by the firstnozzle as the associated manifold is changed relative to the firstnozzle.

At a block 812 the first nozzle is moved relative to the vacuum manifoldto fluidly decouple the inlet port from the sleeve port. For example, anozzle movement mechanism may reposition the first nozzle such that theinlet port of the first nozzle is outside of the sealed sleeve port ofthe manifold through which the first nozzle extends. The fluiddecoupling stops the continued application of vacuum pressure throughthe first nozzle to the component, which allows for the termination ofthe temporary vacuum adhesive between the component and the firstnozzle.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein. Since many possible embodiments may be madeof the disclosure without departing from the scope thereof, it is to beunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

The invention claimed is:
 1. A method of moving material with a pickuptool, the method comprising: moving a first nozzle of a plurality ofnozzles relative to a vacuum manifold of the pickup tool to fluidlycouple an inlet port of the first nozzle with a sleeve port of thevacuum manifold; positioning the pickup tool such that the first nozzleis positioned proximate a component to be picked up by the pickup toolat a first location; moving the component as maintained to the pickuptool by at least the first nozzle; placing the component at a secondlocation; moving the first nozzle relative to the vacuum manifold tofluidly decouple the inlet port from the sleeve port; and moving apositive manifold relative to the first nozzle such that the inlet portof the first nozzle is in fluid communication with a positive sleeveport of the positive manifold.
 2. The method of claim 1, furthercomprising: capturing the component with a vision system prior topositioning the pickup tool proximate the component.
 3. The method ofclaim 2, further comprising: prior to moving the first nozzle relativeto the vacuum manifold to fluidly couple the inlet port with the sleeveport, determining the first nozzle is to be activated based, in part, onthe capturing of the component by the vision system.
 4. The method ofclaim 1, wherein the positive manifold is coupled with the vacuummanifold.
 5. The method of claim 4, wherein the pickup tool comprises amanifold movement mechanism.
 6. The method of claim 5, wherein themanifold movement mechanism is coupled to a base member.
 7. The methodof claim 5, wherein the manifold movement mechanism is coupled to thevacuum manifold.
 8. The method of claim 5, wherein the manifold movementmechanism is coupled to the vacuum manifold and to a base member.
 9. Themethod of claim 4, wherein the moving the positive manifold relative tothe first nozzle occurs via movement of a manifold movement mechanism.10. The method of claim 9, wherein the moving the positive manifoldrelative to the first nozzle occurs via linear movement of the manifoldmovement mechanism.
 11. The method of claim 1, wherein the moving thefirst nozzle of the plurality of nozzles relative to the vacuum manifoldof the pickup tool occurs via a nozzle movement mechanism.
 12. A methodof moving material with a pickup tool, the method comprising: moving afirst nozzle of a plurality of nozzles relative to a vacuum manifold ofa pickup tool to fluidly couple an inlet port of the first nozzle with asleeve port of the vacuum manifold; positioning the pickup tool suchthat the first nozzle is positioned proximate a component to be pickedup by the pickup tool at a first location; moving the component asmaintained to the pickup tool by at least the first nozzle; placing thecomponent at a second location; and moving a positive manifold relativeto the first nozzle.
 13. The method of claim 12, wherein the positivemanifold is coupled with the vacuum manifold.
 14. The method of claim12, wherein the moving the positive manifold relative to the firstnozzle occurs via movement of a manifold movement mechanism.
 15. Themethod of claim 14, wherein the moving the positive manifold relative tothe first nozzle occurs via linear movement of the manifold movementmechanism.